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Old 05-28-2011, 06:14 PM   #1
djcaz_aom
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Morimoto Mini D2S Projector Retrofit

Okay, so this DIY will outline the installation of the Mini Morimoto D2S Bi-Xenon Projectors into one piece headlights.

Parts used:

- Morimoto Mini D2S Projectors Link
- E-46 R Shrouds Link
- JDM One Piece Headlights.
- Mercedes Benz Hella D2S ballasts with Phillips bulbs.

Tools needed:

- Oven or heat gun
- Oven mitts
- Dremel with cut off wheel and sanding barrels
- Masking tape
- Marker
- Black spray paint (optional)
- Aluminum Tape
- Phillips screwdriver
- Various flat-tip screwdrivers
- Solder gun
- Heat shrink tubing
- Wire

This is how I did my retrofit and is an outline on how to do it.

Included in the kit:



Step 1: First remove the clips and the rubber from the corners.




Step 2: Remove the rubber boots.




Step 3: Use either a heat gun or an oven to heat the headlights. I set it at 225 for 7 minutes. Use a screwdriver to pry the clear lens from the housing. More can be found on this procedure in this thread: A Complete USDM Black Housing DIY W/ PICS!!!



Step 4: Remove the chrome piece from the clear lens. It is tacked into place.




Step 5: Remove the clear corner lens from the chrome trim piece. Notice it is tacked in place as well.





**You can now paint your trim piece black if you would like the black housed look. The clear corner lens can also be painted amber if you like.


Step 6: Remove the low beam reflector bucket from the housing.



Step 7: Remove the bulb shield.



Step 8: Now here is where you will have to break out the Dremel. The JDM buckets tilt the H4 bulbs to the side a little bit.


- The centering ring provided with the kit will sit off center, because off the offset.



- Lay the ring, mark the bucket and cut away.






- I trimmed the centering ring a little to get it to fit.



- This is how it should fit.



Step 8: Remove all the hardware from the back of the projector with exception of the big silicone washer. It is white.



Step 9: Run the red and black wires from the projector through the notch left after removing the bulb shield.



Step 10: Insert the projector through the H4 bulb hole in the bucket.





Step 11: Center the projector with the centering ring. Note the projector has a channel for the notch on the centering ring.


Last edited by djcaz_aom; 05-29-2011 at 02:09 PM.
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Old 05-28-2011, 06:14 PM   #2
djcaz_aom
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Step 12: Slide the black rubber o-ring over the threads ensuring not to twist it during the process.


Step 13: Thread on the thread lock ring. It does need to be Hulk tight, as you might break it. You only need 2-3 rows of thread left.


Step 14: Test fit your shrouds. You will probably need to trim them as I did.



Step 15: Put masking tape over the location needing trimming.



Step 16: Mark it and go at it with the Dremel. I trimmed it on the safe side and then fine tuned it.



Step 17: Attach the shrouds to the projector.



Step 18: Re-assemble the clear lens and trim pieces, but not permanently.


Step 19: Re-install the bucket to the housing. Put the two halves together and make sure everything fits. Depending on the size of your shrouds, you may need to trim the clear lens trim piece.





Step 20: Once all is good, reassemble the headlights and place in the oven to soften the headlight sealant.



Step 21: Re-install the rubber corner piece and clips.

**NOTE: I didn't need to aim my headlights first before assembly. The beauty of the JDM one piece headlights is that you can adjust the low beam bucket individually from the high beam bucket.

Next up is the wiring.

Last edited by djcaz_aom; 06-05-2011 at 11:31 PM.
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Old 05-28-2011, 06:17 PM   #3
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Reserved for output pics.



Ready for fine tuning and output shots!!!!





Video off cutoff from low to high:


Last edited by djcaz_aom; 10-10-2011 at 09:00 PM.
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Old 05-28-2011, 11:57 PM   #4
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Old 05-29-2011, 07:43 AM   #5
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It's cool now, I am still uploading the pics.
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Old 05-29-2011, 09:14 AM   #6
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very nice write up man, this is def in my to-do list
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Old 05-29-2011, 01:57 PM   #7
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So what so you have to make ugly cuts into the lights ruining them like the previous projectors or if you wanted to you can put back to stock?

I ask because lack of pics following the last instructions
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Old 05-29-2011, 04:37 PM   #8
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oH SHIET! I'm bookmarking this for sure! Keep us updated
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Old 05-29-2011, 05:25 PM   #9
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Quote:
Originally Posted by Darkcloud View Post
So what so you have to make ugly cuts into the lights ruining them like the previous projectors or if you wanted to you can put back to stock?

I ask because lack of pics following the last instructions
Patience. Every step has a pic. I still haven't finished uploading them all. You will be able to go back to stock. I don't see why you would want to though.
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Old 05-29-2011, 05:35 PM   #10
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How complex is the wiring on these projectors? I used E46 projectors and I had to use a mosfet to get the Bi-Xenon feature to work properly.
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Old 05-29-2011, 05:41 PM   #11
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It is quite simple. I will be posting pics and an outline on how I did it.
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Old 05-29-2011, 09:45 PM   #12
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looking good on the outcome,but deff will be hot once on the wag!
madd props!
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Old 05-30-2011, 03:34 AM   #13
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great write up
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Old 05-30-2011, 10:52 AM   #14
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Im looking forward to this DIY, thanks!
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Old 06-01-2011, 05:36 PM   #15
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Sorry I haven't updated. I am very busy at work. 10+ hours a day. I'll post the rest of the pics on my day off.

Thanks for looking.

Last edited by djcaz_aom; 06-05-2011 at 11:34 PM.
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Old 06-07-2011, 03:16 AM   #16
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Heres mine done in 93 stock lights.

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Old 06-19-2011, 01:45 PM   #17
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Output pix...im bored lol
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Old 07-03-2011, 09:21 PM   #18
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Added a video off the different cut offs.
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Old 07-04-2011, 11:53 AM   #19
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great write up!

and i love the red colour......

i cut my housing as well.but i didn't cut it so big and i painted it flat black,so it's not very visible.

I end up turning the reflector bowl up side down just to let the bottom part of the shroud to be visible(the projector sit higher) because most of the time we see the car from a higher view so it's not that obvious by hiding the top area of the shroud.

cheer~!
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Old 07-04-2011, 01:13 PM   #20
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man love the diy...if i had money and time i would this.....great work guy!!!!
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